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Your Epoxy & Floor Coating Questions Answered – FAQs

What Our Customers Are Asking…

A beautiful example of an expert FloroChip installation by the skilled crews at Gurbitec of Mexico.

Question: How do you apply epoxy flooring in extreme temperatures with fluctuations?

My facility is located in a semi-arid climate that can have 50 degree daytime/nighttime temperature swings. We’ve had trouble with epoxy flooring installations in the past. Do you have any suggestions?

Bob P. of Paso Robles, CA

Answer:

Hi Bob,

Yes, we can help! The Florock concrete floor finishes line is one of the most complete in the industry. We have several products designed for extreme climates. Your local Florock Representative is available to assess firsthand your floor’s traffic, chemical exposure and specific environment. In consultation with our full-service laboratory, your rep can provide you with a custom flooring recommendation uniquely suited to your needs.


Question: How do you avoid epoxy floors blistering and peeling?

Last year, my rotary buddy expanded his facility. The GC applied epoxy to their 28 day old concrete floor and shortly thereafter, the coating started blistering and peeling. What a mess! Now we’re planning a new addition for our plant. How can I avoid having the same problem?

Pat K. of Wichita, KS,

Answer:

Pat, it’s likely that your friend’s concrete was not fully cured at the time of epoxy installation. The industry recommendation of “achieving a 28 day cure prior to coating” is a guideline – not an absolute. If the flooring installer fails to test the slab for relative humidity and then simply preps and applies the epoxy system on Day 29, there’s really no way to predict whether or not the coating will hold. Assuming placement of a proper vapor barrier under the new slab, and barring other site or environmental sources of excess concrete moisture, using convenient probes to measure the relative humidity of a new slab as it’s curing* is recommended. This is the most cost-effective way to help ensure your new concrete is ready for coating. Our team of experts is available to help, so be sure to give us a call!

* In accordance with ASTM F2170, “Standard Test Method for Determining Relative Humidity in Concrete Floor Slabs Using In Situ Probes”


Question: What’s a budget-saving epoxy floor restoration solution?

What am I supposed to do about the floors I’m seeing out here these days? The facility owners seem to be waiting until the concrete’s practically falling apart before they even think about calling. Then, they don’t want to pay for the inch of epoxy mortar it’ll take to restore the substrate! Any ideas?

Bill B. of Rochester, NY

Answer:

Hi Bill,

Thanks for your inquiry. This is a story we hear far too often. Fortunately, we have the solution! The FloroSurface Cementitious Underlayment System is a great budget-saving way to restore damaged concrete before proceeding with application of a high performance traffic surface. The high build underlayment can be installed at almost any thickness and makes an ideal economical substrate for your Florock topping of choice.


Question: What’s the best way to recoat an uneven concrete slab floor for a seamless epoxy finish with skid resistance?

As an architect, my latest challenge is the conversion of an old warehouse into a high-tech packaging area.  The surface of the existing bare concrete floor is an uneven mess, but I’d like to avoid re-pouring the slab for budgetary reasons. The finish will need to be seamless epoxy with skid-resistance. Do you have a written specification I can use?

Stefanie R. of Albuquerque, NM

Answer:

Hello Stefanie,

Thanks for asking! Yes, we have a number of architectural specifications available. They are publication-ready and easy to copy/ paste into your document.

Without seeing the floor, however, it’s hard to know the best way to build up your degraded substrate. For example, would 1/4” FloroBuild Epoxy Mortar System be required or would a 3/8” – 1/4” thick FloroCrete RT Urethane Mortar application be more appropriate?


Your local Florock Representative can help you specify the ideal high-performance flooring system for your project. We offer this service at no charge! Just give a call at 1-800-Florock (356-7625).


Question: What is meant by “mils” in terms of epoxy floor coatings?

Your epoxy flooring literature uses the term “mils” a lot.  I read on the internet that a “mil” is short for “millimeter”. But a painter friend of mine said he thinks it’s something different. Can you please explain the term?

Stanley W. of Detroit, MI

Answer:

Great question, Stanley! Actually, your painter friend is correct. As you know, a millimeter (mm) is 1/1000th of a metric meter. However, in the paint and coatings world, the term “mil” is an English unit, meaning 1/1000th of an inch.

For example, when a contractor applies a layer of epoxy at a thickness of 20 mils, it means the coating is 20/1000 inches thick, or when converted to metric units, 0.508 millimeters (mm) thick.  From this, it’s easy to see that “20 mils” (0.508 millimeters) is very different “20 millimeters”!


Question: How do you know the correct amount of sand to use when creating a heavy duty mortar, using FloroBuild and Florock aggregate blend?

When adding sand to 100% solids epoxy to create a heavy duty mortar, my previous employer taught me to figure “1+1=1.6”.  In other words, 1 gallon of sand, added to 1 gallon of blended epoxy, yields 1.6 gallons of blended mortar mix. My new boss uses FloroBuild resin and your special aggregate blend. The old math doesn’t seem to work anymore, but the product goes down like a dream. Can the sand really make that much of a difference?

Bob R. of Richmond Beach, VA

Answer:

Thanks for asking, Bob. The answer is yes! The different grades of aggregate and the way they fit together in a tight matrix make a great deal of difference – both in the ease of installation and in the performance of the system. Of course, a quality floor epoxy like FloroBuild, designed especially for concrete resurfacing with a power trowel, is certainly part of the equation.

Be sure to call us if you have additional questions at 1-800-Florock (356-7625).  We’re happy to help!


Question: Why should we use FloroCrete vs. FloroPoxy or FloroThane?

We’ve installed your products for years and our customers have been very happy. Is there a reason to use FloroCrete versus your epoxy flooring?

Bob W. of Mokena, IL

Answer:

Thanks for your business, Bob! As you know, the broad Florock line of concrete floor finishes can fulfill almost any industrial, commercial or institutional need. FloroPoxy and FloroThane provide outstanding protection for many applications. However, when you come across a floor that is exposed to high concentrations of chemicals, thermal shock/cycling (including steam-cleaning) and heavy traffic, think “FloroCrete”. Then, call your local Florock Rep to discuss the details!


Question: How do you determine which FloroCrete product is best for my concrete floors?

How do I know which FloroCrete product is right for my situation?

John K. of Spokane, WA

Answer:

John, the type of FloroCrete recommended depends upon the level of traffic, chemical exposure and thermal shock the floor will receive, as well as the appearance and skid-resistance required. The installation technique necessary, the depth of material needed, the room size, and even whether the floor is level or sloped, can influence the decision. You’ll want to discuss your unique situation with your local Florock Rep.


Question: What floor colors does Florock offer with FloroCrete?

What color choices does my customer have when I install FloroCrete?

Sandy B. of Tupelo, MS

Answer:

Sandy, FloroCrete P, SLX, RT and HD are available pre-pigmented in Tile Red or Grey, and the Neutral versions are field-tintable with FloroCrete Powder Pigments. Solid colored, high performance grout and finish coats are available, while a variety of other decorative toppings may be a choice in some applications. And don’t forget, FloroCrete Cove is available for creating radius or cant coves, as well as for patching. Your local Florock expert is available to provide you with further information.


Question: How do I properly treat control joints in concrete when installing an ESD concrete floor coating system?

What is the proper treatment of control joints when installing an ESD concrete coating system? Joint filler is not dissipative and it is often not practical to ground within every joint-bordered area.

Tom M.

Answer:

Hi Tom,

Thanks for your question. It is important to remember that ESD systems are installed over a coat or two of insulative epoxy. The floor is then grounded to earth grounding points. So ideally, it is best to install the joint material before applying the topcoat of FloroPoxy ESD or CON. These specialty floor coatings then bridge the joint material, providing a dissipative surface throughout the concrete floor. FloroPoxy ESD Electrostatic Dissipative Epoxy and FloroPoxy CON Conductive Epoxy possess sufficient flexibility to allow normal joint movement.

In circumstances where the joint material must be installed after the ESD system is already placed, each isolated slab should either be given its own earth ground (as you say, not very practical), or should be “reconnected” to adjacent slabs. The latter can be achieved by bridging the joints using ESD strapping.

I hope this answers your question.  Please feel free to call us at 1-800-Florock (356-7625) with any further questions.


Question: What materials are best when patching and leveling low spots in concrete floors?

In patching cracks and filling in low spots on a concrete floor, what materials are most compatible with your cement floor paint and what is the minimum thickness of a patch?  Should the patching be done before or after surface prep?  What kind of finish should the patch have?

Garry Z.

Answer:

Hi Garry,

Thanks for your great question!  Since moving joints and cracks require a different approach, the following assumes that any cracks to be repaired are non-moving.

All patching should be done after mechanical prep on the concrete floor has been completed. The type of epoxy flooring system you intend to apply over the patches will determine the finished texture of the patch:  When going over the patches with a thin mil or broadcast epoxy floor coating, leave a smooth surface on the repair; if a troweled resurfacer system will be applied, finish the repair with a texture.

Proper treatment of a damaged substrate prior to applying traffic coats is one of the most important – and, unfortunately, most often overlooked – aspects of industrial flooring work. Florock offers a variety of concrete crack repair and cement floor patching products to accommodate different needs:

FloroGel is a highly thixotropic, 100% solids epoxy that can be placed in holes up to 1.5 inches deep. It also lends itself to feather-edging the repair area to “zero” inches. FloroGel is ready for recoating with epoxy floor paint in 2-3 hours, depending on depth of application — The deeper the fill, the quicker the cure.

FloroBuild HD is a trowelable, 100% solids heavy duty epoxy mortar. Aggregate is employed in the mix to increase FloroBuild’s compressive strength to >10,000 psi, compared with the standard 4,000-6,000 psi of concrete. This system is typically installed at 1/4″ to resurface badly spalled concrete and can also be used for deeper fills.

FloroCrete Cove is a trowelable urethane mortar that is used to patch concrete floors in conjunction with installation of other FloroCrete flooring. In many cases, this unique material can be applied over damp substrates, including “green” concrete, making it a high value repair product for food processing and similar facilities.


Question: What concrete floor paint systems will hold up against oils, fluids and solvents?

Our maintenance bay floors need help. Despite our cleaning schedule, the dripping oil, fluids, and solvents are eating away at whatever epoxy coating is currently on the concrete. I’d sure hate for some inspector to walk through here now! Do you have a cement floor paint that will hold up? And is it available in a satin finish?

Linda Z. of Tulsa, OK

Answer:

Hello Linda,

Thanks for your inquiry.  And Yes! We have just the concrete resurfacing system for your situation!  After cleaning, mechanical preparation and patching, one or more layers of FloroPoxy, followed by a coat of FloroThane MC/HT with MC/HT Satin Powder, will provide your vehicle bay floors with the high tech floor paint protection they need. With proper maintenance, your industrial flooring will look great for years to come. Your local Florock Representative can introduce you to a trained professional installer in your area. 


Have a question about epoxy floor coatings in your facility? Ask the experts at Florock or give us as call!